Disposable absorbent undergarment for males

ABSTRACT

A disposable absorbent garment includes a body chassis having a terminal front waist edge, a terminal back waist edge longitudinally spaced from the terminal front waist edge, a first length defined between the terminal front waist edge and the terminal back waist edge, and a laterally extending centerline defined half way between the terminal front and back waist edges. An absorbent insert is fixedly secured to the body chassis. The absorbent insert has a retention region including an absorbent material. The retention region has first and second longitudinally spaced boundaries and a second length defined between the first and second boundaries. The second length is less than or equal to 50% of the first length, and at least 70% of the second length is positioned between the centerline and the terminal front waist edge. There is no absorbent material disposed outside of the retention region defined between the first and second boundaries. In one embodiment, the body chassis is formed from separate front and rear body panels. A method of assembling a disposable absorbent garment is also provided.

BACKGROUND

The present invention relates generally to disposable undergarments, andin particular, to a disposable undergarment particularly suited for amale user.

Typically, incontinence garments are not designed specifically for maleusers. Rather, most incontinence garments, such as diapers or pant-type,pull-on garments, include an absorbent material that is positioned andsized to receive both urine and feces. Such types of garments aretherefore designed to handle additional waste than what is necessary formost male users, especially males concerned primarily with urinaryincontinence. In addition, urine emitted by males and females isdirected to different areas of an undergarment, and garments targeted atfemales do not necessarily provide optimum coverage for male users.Consequently, such products may unnecessarily sacrifice comfort at anincreased cost.

One solution for the particular problems associated with maleincontinence is to provide an absorbent product that is held close tothe male user's body with conventional, non-disposable underwear. Suchproducts can be difficult to use with immobilized or bed-ridden users,however, where the application and removal of conventional underwear ismade more difficult. In addition, the absorbent product is located bythe user relative to the underwear and body, which can lead tosuboptimal results if not properly positioned. Moreover, if theconventional underwear is inadvertently soiled, it must be washed ordisposed of with additional costs and inconvenience associatedtherewith. In addition, the various layers of the absorbent product, incombination with the underwear, can provide a bulky appearance andreduce the overall comfort of the user.

SUMMARY

Briefly stated, in one aspect, a disposable absorbent garment includes abody chassis having a terminal front waist edge, a terminal back waistedge longitudinally spaced from the terminal front waist edge, a firstlength defined between the terminal front waist edge and the terminalback waist edge, and a laterally extending centerline defined half waybetween the terminal front and back waist edges. An absorbent insert isfixedly secured to the body chassis. The absorbent insert has aretention region including an absorbent material. The retention regionhas first and second longitudinally spaced boundaries and a secondlength defined between the first and second boundaries. The secondlength is less than or equal to 50% of the first length, and at least70% of the second length is positioned between the centerline and theterminal front waist edge. There is no absorbent material disposedoutside of the retention region defined between the first and secondboundaries. In one embodiment, the body chassis is formed from separatefront and rear body panels. A method of assembling a disposableabsorbent garment is also provided.

The various aspects provide significant advantages over other disposableundergarments and methods. For example and without limitation, theforward positioning and smaller size (e.g., shorter length) of theretention region is ideally suited for male incontinence needs. At thesame time, and due to the specific positioning of the absorbent insert,the proportion of absorbent material relative to the size of the overallgarment can be reduced. Such reductions can result in substantialsavings with respect to material costs. In addition, the absorbentgarment is less bulky in the rear region, due to the lack of excessabsorbent material, and thereby provides improved fit, comfort andappearance for the male user. Moreover, since the absorbent insert isfixedly secured to the body chassis, it is automatically locatedrelative to the user's body by the application of the absorbent garment,thereby reducing the possibility that the absorbent insert will not beproperly located.

The foregoing paragraphs have been provided by way of generalintroduction, and are not intended to limit the scope of the followingclaims. The presently preferred embodiments, together with furtheradvantages, will be best understood by reference to the followingdetailed description taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of one embodiment of an absorbent garment in anunfolded configuration with an absorbent insert connected to a bodysidesurface of a front and rear body panel.

FIG. 2 is a cross sectional view of the absorbent garment shown in FIG.1 taken along line 2-2.

FIG. 3 is a cross sectional view of the absorbent garment shown in FIG.1 taken along line 3-3.

FIG. 4 is a cross-sectional view of the absorbent garment shown in FIG.1 taken along line 4-4.

FIG. 5 is a plan view of another embodiment of an absorbent garment inan unfolded configuration with an absorbent insert connected to abodyside surface of a front and rear body panel.

FIG. 6 is a plan view of another embodiment of an absorbent garment inan unfolded configuration with an absorbent insert connected to agarment side surface of a front and rear body panel.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

It should be understood that the term “longitudinal,” as used herein,means of or relating to length or the lengthwise direction 500. The term“laterally,” as used herein, means situated on, directed toward orrunning from side to side in a direction 502 substantially perpendicularto the lengthwise direction.

The term “bodyside” should not be interpreted to mean in contact withthe body of the user, but rather simply means the side that would facetoward the body of the user, regardless of whether an undergarment isactually being worn by the user and regardless of whether there are ormay be intervening layers between the component and the body of theuser. Likewise, the term “garment side” should not be interpreted tomean in contact with the garments of the user, but rather simply meansthe side that faces away from the body of the user, and therefore towardany outer garments that may be worn by the user, regardless of whetherthe undergarment is actually being worn by a user, regardless of whetherany such outer garments are actually worn and regardless of whetherthere may be intervening layers between the component and any outergarment.

The phrases “removeably attached,” “removeably attaching,” “removeablyconnected,” “removeably engaged,” “releasably attached,” “releasablyconnected,” or “releasably engaged,” and variations thereof, refers totwo or more elements being connected or connectable such that theelements tend to remain connected absent a separation force applied toone, both or all of the elements, and where the elements are capable ofbeing separated upon the application of a separation force. The requiredseparation force is typically beyond that encountered while wearing theabsorbent garment.

The phrases “fixedly secured,” “fixedly engaged,” “fixedly attached,”“fixedly connected,” and variations thereof, refers to two or moreelements being connected or connectable such that they are notdisconnected or otherwise separated, and are not intended to beseparated or disconnected by the end user, during the normal operationand use of the absorbent garment. Moreover, the separation of twoelements being so connected is likely to damage or make unusable atleast one of the two elements.

The terms “connecting,” “coupled,” “attached,” and “secured,” andvariations thereof, broadly covers two or more items being directlyconnected one to the other, or by way of one or more intervening membersor components.

Referring to FIGS. 1 and 4, an undergarment 2 includes a body chassisformed from a first, front body panel 4 and a second, rear body panel 6.The terms “body chassis” and “body panel” refers to the portion(s) ofthe undergarment, whether made of one or more layers or substrates or ofone or more pieces or components, that is/are fitted circumferentiallyaround at least a portion of the waist region of the user, including forexample the user's lower back, buttock, hips and abdomen. The first andsecond body panels each have an inner, bodyside surface 10 and an outer,garment side surface 12. Referring to the embodiments of FIG. 1, thefirst, front body panel 4 has a first terminal crotch edge 14 forming acrotch portion 16 and leg opening portion 18 and a second terminal waistedge 20 which, in one embodiment, is linear but can assume other shapes.Likewise, the second, rear body panel 6 has a first terminal crotch edge22 forming a crotch portion 24 and a leg opening portion 26 and a secondterminal waist edge 28, which is shown linear but can assume othershapes. In various embodiments, the terminal crotch edges can besubstantially linear, curvilinear, or have any other shape. For exampleand without limitation, the crotch portion and leg opening portions canform a generally sinusoidal curve, with one or both of the leg openingportions and/or crotch portions having a convex or concave contour. Ofcourse, it should be understood that the crotch edge can have many formsand shapes not expressly disclosed herein. Each of the first and secondbody panels has an outboard side edge 30, 32 formed along the outerperiphery of the opposite side portions of the first and second bodypanel. It should be understood that the outboard side edges of the frontand rear body panels can have the same or different lengths relative toeach other.

In one embodiment, a plurality, meaning two or more, elastic elementsare secured to each of the first and second body panels. In preferredembodiment, a plurality of elastic elements are spaced acrosssubstantially the entire waist portion of the front and rear body panel4, 6, although they may be spaced across a lesser length. For example,elastic elements can extend along the upper waist portion and along thelower terminal edge defining in part a leg opening 34.

In one embodiment, the front body panel has a “non-elasticized” areawherein there are no elastic elements, or other elastic or elastomericbacking members, incorporated therein or making up any portion of thethickness or cross-section of the body panel at that area. It should beunderstood, that in an alternative embodiment, one or more separatewaist bands, with or without elastic elements, can be secured to one orboth of the rear and front body panels, preferably along the upperterminal edges 20, 28 thereof. Likewise, one or more separate leg bandscan be secured to one or both of the rear and front body panels alongthe leg open portions 18, 26 adjacent the leg openings 34.Alternatively, one or both of the body panels can be formed without anyelastic elements. In other embodiments, the entirety of the front and/orrear body panels are elasticized.

The various waist and leg elastic elements can be formed from rubber orother elastomeric materials. One suitable material is a Lycra® elasticmaterial. For example, the various elastic elements can be formed ofLycra® XA Spandex 540, 740 or 940 decitex T-127 or T-128 elasticsavailable from E.I. duPont De Nemours and Company, having an office inWilmington, Del.

Referring to FIGS. 3 and 4, each body panel 4, 6 is preferably formed asa composite, or laminate material, otherwise referred to as substratesor laminates, with an elastic core 136 sandwiched therebetween. In oneembodiment, the elastic core 136 is made of an elastomeric film ornonwoven elastic or stretchable material including for example but notlimited to styrenic copolymers of polyisoprene, polybutadiene orpolyolefin, copolymers of polyolefins, natural or styrene butadienerubber, polyurethanes, polyamides, polyesters, and co-extrusions/blendsof the aforementioned materials. The elastic core 136 can be formed as amembrane or from the plurality of elastic strands 36, as describedabove. In one embodiment, two or more layers 40 are bonded to theelastic core 136, and/or each other, with various adhesives, such as hotmelt, or by other techniques, including for example and withoutlimitation ultrasonic bonding and heat pressure sealing. In oneembodiment, the two layers are made of a non-woven material such as aspunbond material, a bonded carded material or other known materials. Inthis way, the body panels are made of a stretchable/elastic material.

It should be understood that the body panels can be made of a singlelayer or substrate of non-woven material, a bi-layer substrate made ofnon-woven materials without an elastic core, or more than two layers orsubstrates. Of course, it should be understood that other knitted orwoven fabrics, non-woven fabrics, elastomeric materials, polymer films,laminates and the like can be used to form one or more of the body panellayers. The term “non-woven” web or material, as used herein, means aweb having a structure of individual fibers or filaments that areinterlaid, but not in an identifiable manner and without the aid oftextile weaving or knitting, as in a knitted or woven fabric.

In one embodiment, the body panel material can be secured to the elasticcore, such as an elastomeric layer or elastic strands or ribbons, whichhave been elongated and retracted, such that the material is gatheredwhen the elastic element(s) are relaxed. Alternatively, the material canbe gathered and laminated to non-elongated elastic elements. In onepreferred embodiment, the body panel includes a gathered elasticlaminate made from nonwoven base sheets bonded with elongated elasticelements sandwiched therebetween.

In various preferred embodiments, the body panel material may besubstantially permeable to air or substantially impermeable to air. Thebody panel material also may be substantially liquid-permeable orsubstantially liquid-impermeable. In particular arrangements, the bodypanel material may be substantially nonelastomeric. In other aspects,the body panels can include an elastomeric material that iselastomerically stretchable at least along one or both of the lateralarticle width and the longitudinal article length. Examples of suchelastomeric composite materials can include a continuous filamentstretch bonded laminate (CFSBL), a vertical filament laminate (VFL),neck-bonded-laminate (NBL), a stretch-bonded-laminate (SBL), anecked-stretch bonded laminate (NSBL) or a necked-thermal laminate, orthe like, as well as combinations thereof. Exemplary CFSBL, NBL, SBL,and NSBL materials are described in U.S. Pat. Nos. 5,226,992, 4,981,747,4,965,122, 5,336,545, 5,385,775, 5,514,470, 4,720,415, 4,789,699,4,781,966, 4,657,802, 4,652,487, 4,655,760, 5,116,662 and 5,114,781, and6,323,389, all of which are hereby incorporated herein by reference.Exemplary VFL materials are described in U.S. Provisional PatentApplication Ser. No. 60/204,307, filed May 15, 2000 and entitled “Methodand Apparatus for Producing Laminated Articles,” and PCT application WO01/88245 A2, both assigned to Kimberly-Clark Worldwide, Inc., theAssignee of the present application, with the entire disclosures of bothbeing hereby incorporated herein by reference. Such laminates canprovide an improved combination of cloth-like feel and elastomericstretchability. The body panels can be composed of materials that areelastic or elastomeric and exhibit biaxial stretch characteristics orlateral/longitudinal stretch characteristics, or which are extensiblecomposites. Additional waist and leg elastic elements can be added to,but are not necessarily required by, the body panels. In one embodiment,the body panel can be made of a film or non-woven that is attached, byway of adhesives or thermal bonding, to an extensible non-wovenmaterial. Alternatively, the body panel can be made of a low modulusfilm such as ethylene methyl acrylate (EMA).

As shown in the embodiment of FIG. 1, the entirety of the body panels 4,6, and portions of the crotch member 50, are elasticized, such that theentirety of each of the body panels can elongate and conform to the bodyof the user without any substantial spacing between the body panel andthe user's body, and without the attendant bulkiness of anon-elasticized material.

In one embodiment, the body panels are breathable, cloth-like,multi-directional nonwoven laminates with stretch or extensibleproperties. In one embodiment, the non-woven layers are pre-necked, forexample between about 10% and about 80%, in the longitudinal direction,which provides extensibility in the longitudinal direction with minimalforce.

In one embodiment, the body panel members 4, 6 are made of non-wovenlaminates of two layers of 0.55 osy polypropylene spunbond material withelongated strands of Lycra® leg and waist elastics sandwiched betweenthe spunbond layers and thereafter adhesively bonded. In otherembodiments, two layers of 0.060 osy polypropylene spundbond materialcan be used. In one particular embodiment, the body panel is a nonwoven,wire-weave spunbond polypropylene fabric composed of about 1.6 denierfibers formed into a web having a basis weight of about 0.6 osy. Onesuitable non-woven material is the Corinth 0.60 osy, 1.6 dpf wireweave,nonwettable Metallocene (EXXON ACHIEVE 2854 PP) spunbond materialmanufactured by Kimberly-Clark Corporation, the Assignee of the presentapplication. In one embodiment, the body panel material is necked in thecross direction. As used herein, the term “necked,” and variationsthereof, refers to any material that has been constricted in at leastone dimension by applying a tensioning force in a direction that isperpendicular to the desired direction of neck-down. Processes that maybe used to constrict a material in such a manner include, for exampleand without limitation, drawing processes. The elastics are thenelongated in the machine direction and secured to the body panelmaterial. The elastics are then allowed to retract so as to gather thenecked spunbond material in the lateral (machine) direction therebycreating an elastically gathered non-woven body panel with longitudinalextensibility. The term “gather,” and variations thereof, as used hereinmeans puckered, or contracted into folds or wrinkles, which should beunderstood as including micro-pleats.

In this way, the body panel can be elongated in both the longitudinaland lateral direction to conform to the body of the user when thegarment is applied thereto. In particular, as the user pulls the garmentup over their hips, the non-woven laminate body panels stretch in thelateral direction while the leg regions of the front and rear bodypanels conform to the crotch and body lines of the user. At the sametime, the body panel material extends in the longitudinal direction toconform to the buttocks and stomach of the user. The extensibility ofthe body panels follows the natural curvature of user's body to provideconformance thereto. As the body panel extends in the longitudinaldirection, the spacing between the laterally extending elastic elements,incorporated in one embodiment, will increase.

The body panel non-woven material is preferably substantiallyhydrophobic, which may optionally be treated with a surfactant orotherwise processed to impart a desired level of wettability andhydrophilicity.

It should be understood that an outer cover can be disposed over andsecured to the front and rear body panels and crotch member of FIG. 1.In such an embodiment, the outer cover forms part of the overall bodychassis and runs from the terminal waist edge of the front body panel tothe terminal waist edge of the rear body panel. The outer cover can bemade of any material, including the various non-woven, extensible and/orstretchable materials disclosed herein.

In another embodiment (not shown), the crotch edges of the front andrear body panels overlap and are joined one to the other, rather thanbeing spaced apart, so as to form a “two-piece” body chassis (as opposedto a three-piece construction which utilizes a third crotch memberpiece, such as an absorbent insert, to form the chassis). The retentionportion, which can be formed as two pieces, is sandwiched between layersof each of the front and rear body panels. Alternatively, the retentionportion is formed as part of an absorbent insert that is secured to thebodyside surface of the joined front and rear body panels.

In another embodiment, shown in FIG. 6, the body chassis 202 includes atop sheet 204 and back sheet 206 that extend from the front to the rearterminal waist edges 20, 28 and form the body chassis, including frontand rear bodypanels integrally joined with a crotch portion. The topsheet and back sheet can be made from any of the various materialsdisclosed herein. A retention portion 70 is disposed between the topsheet 204 and back sheet 206. Alternatively, a separate absorbentinsert, including a retention portion disposed between a top sheet and aback sheet, is secured to the bodyside surface of the body chassis.

In yet another embodiment, shown in FIG. 5, a body chassis 302 has aT-shape, with a laterally extending waist portion 304 and alongitudinally extending crotch portion 306. The waist portion 304 wrapsaround the body of the user and is secured to a free end 310 of thecrotch portion 306 that extends upwardly adjacent the front of the user,for example to the garment side surface of the crotch portion. The waistportion can be elasticized or not, and includes a pair of fasteners 308secured to opposite sides thereof. The crotch portion can include alanding material suitable for engaging the fasteners. The waist portiondefines both the rear waist edge 28, and the front waist edge 20 whenwrapped around the user, while the end of the crotch portion can furtherdefine the front waist edge 20. It should be understood that the waistedge 20 defined by the crotch portion 306 does not necessarily have tobe aligned with the waist edge 20 defined by the waist portion 304 whenthe garment is applied to the user. In one embodiment, the crotchportion 306 and the waist portion 304 are integrally formed from one ormore layers and are continuous between the front and rear waist edges.In such an embodiment, a retention portion can be sandwiched, forexample, between a continuous top sheet and back sheet. In anotherembodiment (not shown), the waist portion is formed as a separate belt,which is secured for example to an absorbent insert having one endconnected thereto.

In yet another embodiment (not shown), a “five-piece” garment includesan absorbent insert that runs the length of the garment and has oppositeends that define the front and rear waist edges. Two pairs of side bodypanels, or ears, are connected to opposite sides of the absorbent insertadjacent opposite ends thereof. The lateral free edges of the side bodypanels can then be joined to form leg openings.

In yet another embodiment (not shown), the chassis, which can be formedfrom a top sheet and back sheet, is rectangular in shape, with theretention portion disposed between the top sheet and back sheet, or witha separate absorbent insert secured to the body side surface of thechassis. In this embodiment, the chassis can be pleated such that it canbe expanded laterally outward to fit around the body of the user.

Referring to FIGS. 1 and 6, the crotch member 50 of the variousundergarments, whether formed as a separate absorbent composite orformed in part by the body chassis, connecting the front and rear bodypanels 4, 6 can be folded such that the side edges 30, 32 of the frontand rear body panels 4, 6 are aligned, whereinafter they can be fixedlysecured at a seam to form the leg opening 34. The seam can be formed bybonding, sewing or otherwise attaching the side edges. Alternatively,the product can remain “open,” wherein the body panels are releasablysecured with one or more fastening members (not shown).

In one embodiment, the garment includes a combination of side edges thatare secured to form a seam and fastening members that allow the fit ofthe undergarment to be adjusted. For example, in one embodiment,fastening members are preferably attached to the front body panel andextend inboard relative to the outboard side edge of the front bodypanel from an attachment location, which is preferably spaced inboardfrom the side edge. A landing member can be formed on or secured to thebody panel to receive a refastenable portion of the fastening member.One or more lines of weakness can be provided along the front or rearbody panel such that one or both of the body panels are breakable. Thelines of weakness can comprise a perforation or other series of cuts, athinning, breakage or separation of material, or a strip of a differentkind of material bridging portions of the body panel that is more easilytorn or broken than the other material thereof, which allow a user orthe manufacturer to separate portions of the body panel. For example,the undergarment can be broken along the lines of weakness after thegarment is applied to a user, or beforehand. In one embodiment, thefastening members are secured to the garment-side surface of the bodypanel.

It should be understood that, in other embodiments, the fasteningmembers can be secured to the rear body panel and engage the front bodypanel or, conversely, can be secured to the front body panel and engagethe rear body panel, preferably along at least a portion that is notelasticized. In one embodiment, the fastening members are fixedlysecured to the outer, garment-side surface of the front and/or rear bodypanels, and releasably engage the outer, garment-side surface of thefront and/or rear body panels, although it should be understood that thefastening members could be fixedly secured to an inner body-side surfaceof front and/or rear body panels and releasably engage an inner,body-side surface of the front and/or rear body panels.

When incorporated into a disposable absorbent undergarment, thefastening members can include a refastenable portion, such as an arrayof hook members, adhesives, such as pressure sensitive adhesives,buttons, zippers, snaps and other releasable and reattachable fasteningdevices. In various embodiments, the fastening member includes one, twoor more than two tab members. In one embodiment, the fastening memberscomprise a carrier member, which is preferably fixedly secured to theside portions of the front body panel with adhesive bonds, sonic bonds,thermal bonds, pinning, stitching or other known types of attachment. Inalternative embodiments, the fastening members can be fixedly secured tothe rear body panel or to one or both of the front and rear body panels,for example, at the seam, as explained above.

Referring to the embodiments of FIGS. 1-4, the crotch member 50,otherwise referred to as an absorbent insert, is formed as a separatesubassembly connected to either the bodyside or garment side surface 10,12 of the body panel members 4, 6. Various garments having a“three-piece” construction including a front and rear body panelconnected with an absorbent insert include for example and withoutlimitation the Depend® Protective Underwear and Depend® RefastenableUnderwear, both available from Kimberly-Clark Worldwide Corporation, theassignee of the present application. In either embodiment, the crotchmember 50 has first and second opposed terminal end edges 60, 62. Thecrotch member 50 bridges the gap between the terminal edges 14, 22 ofthe body panels 4, 6 and is connected respectively to those body panelswith an adhesive at adhesive regions.

In particular, the crotch member 50 has first and second end portions102, 104 that overlap the front and rear body panels 4, 6 respectivelyand are connected thereto with the adhesive at the adhesive regions. Inone embodiment, the entirety of the end portions 102, 104 of the crotchmember that overlaps the body panels can be attached thereto. The crotchmember 50 can be secured to the body panels when they are in a stretchedor unstretched condition. The crotch member can be secured to the bodypanels. In other embodiments, only a portion of the crotch member aresecured to the body panels. In the various embodiments, the adhesiveregion is formed by a continuous or intermittent swirl pattern, a lineof adhesive, such as a bead, or a pattern of dots of adhesive.

In one embodiment, shown in FIGS. 1-4, the crotch member is configuredas an absorbent insert 50 that includes a substantially liquid permeabletop sheet 64, or liner, and a substantially liquid impermeable backsheet 66. A retention portion 70 is disposed or sandwiched between thetopsheet and the backsheet, which are connected. It should be understoodthat the term “absorbent insert” refers to any material or assemblycapable of absorbing liquids or bodily exudates, and may be formed froma single material or component, for example a retention portion, or canbe formed as a composite of several components. An absorbent insert ofthis type of construction can be used in any of the one-piece,three-piece, T-shaped, five-piece or two-piece body chassis garmentsdescribed above.

Referring to FIGS. 1-4, the top sheet 64, back sheet 66 and othercomponents of the absorbent insert can be joined for example withadhesive bonds, sonic bonds, thermal bonds, pinning, stitching or anyother attachment techniques known in the art, as well as combinationsthereof. For example, a uniform continuous layer of adhesive, apatterned layer of adhesive, a sprayed pattern of adhesive or any arrayof lines, swirls or spots of construction bonds may be used to join thetopsheet and backsheet, or any of the other components described herein.

In one embodiment, one or more crotch elastic members 38 are sandwichedbetween the top sheet 64 and backsheet 66 along the side edges thereof.The elastic members 38 can extend the entire longitudinal extent of theabsorbent insert, or along only a portion thereof.

Additional layers, including for example, a liquid acquisition anddistribution layer 72, also referred to as a surge or transfer layer,are also preferably incorporated into the absorbent insert. In oneembodiment, the transfer layer does not run the entire length of theabsorbent insert and is shorter than the retention portion.

In one embodiment, the retention portion 70, transfer layer 72 and othercomponents, such as tissue layers, are free floating (unattached)between the back sheet 64 and the top sheet 66, which are secured alongonly the peripheral edges thereof. Alternatively, the retention portion70, transfer layer 72 and other components are minimally attached to oneor both of the back sheet 66 and top sheet 64. For example, theretention portion can be secured to the back sheet along an attachmentlocation positioned along the longitudinal centerline 112 of theretention portion. Alternatively, or in combination with the back sheetconnection, the transfer layer or retention portion can be minimallyattached to the top sheet. In this way, the retention portion 70,transfer layer 72 and other components do not impede or substantiallyaffect the lateral stretchability and extensibility of the absorbentinsert 50 and in particular the top sheet and back sheet, at least oneof which is secured to the body chassis.

In another alternative embodiment (not shown), the retention portion issecured along the centerline at a point midway between the two ends ofthe retention portion. In this embodiment, the retention portion alsodoes not restrict or impede the stretchability and extensibility of theabsorbent insert, and in particular the top sheet and back sheet, in thelateral or longitudinal directions 500, 502.

In other embodiments, the top sheet is indirectly joined to thebacksheet by affixing the topsheet to intermediate layers, such as thesurge layer or retention portion, which in turn is affixed to thebacksheet. The absorbent insert also may include barrier cuffs, orleakage control shields, formed along the opposite longitudinallyextending edges of the absorbent composite.

In one embodiment, the back sheet 66 is a stretchable, elastic, liquidimpervious member. Alternatively, the back sheet may be liquidpermeable, e.g., when an additional barrier layer is used with theretention portion. In one embodiment, shown in FIGS. 1-4, the back sheet66 is a laminate structure made of a stretchable, elastic material, suchas an elastomeric film 80, which is laminated to an extensible non-wovenmaterial layer 82. It should be understood that the backsheet can beformed from a single layer or substrate or more than two layers orsubstrates. The backsheet can be stretchable in both the lateral andlongitudinal direction, or be stretchable in one direction andextensible in the other.

The backsheet 66 prevents various bodily fluids and exudates fromwetting or otherwise contaminating various bedding or outer garmentsworn by the user over the absorbent garment. The backsheet can be madeof the same materials described above in connection with the bodypanels. In one embodiment, the backsheet can include a film, which canbe made of the various materials described above.

The backsheet may include a micro-porous, “breathable” material whichpermits gases, such as water vapor, to escape from the absorbent garmentwhile substantially preventing liquid exudates from passing through thebacksheet. For example, the breathable backsheet may be composed of amicroporous polymer film or a nonwoven fabric which has been coated orotherwise modified to impart a desired level of liquid impermeability.For example, a suitable microporous film can be a PMP-1 material, whichis available from Mitsui Toatsu Chemicals, Inc., a company havingoffices in Tokyo, Japan; or an XKO-8044 polyolefin film available from3M Company of Minneapolis, Minn. The backsheet may also be embossed orotherwise provided with a pattern or matte finish to exhibit a moreaesthetically pleasing appearance. In one embodiment, the absorbentinsert includes a breathable stretch thermal laminate (BSTL).

In various embodiments, where a component, such as the backsheet isconfigured to be permeable to gas while having a resistance and limitedpermeability to aqueous liquid, the liquid resistant component can havea construction which is capable of supporting a selected hydrohead ofwater substantially without leakage therethrough. A suitable techniquefor determining the resistance of a material to liquid penetration isFederal Test Method Standard FTMS 191 Method 5514, 1978, or anequivalent thereof.

In one embodiment, the backsheet is sufficiently impermeable to liquidand semi-liquid materials to substantially prevent the undesired leakageof waste materials, defined as exudates, including for example urine andfeces. For example, the backsheet member can desirably support ahydrohead of at least about 45 centimeters (cm) substantially withoutleakage. The backsheet member can alternatively support a hydrohead ofat least about 55 cm, and optionally, can support a hydrohead of atleast about 60 cm, or more, to provide improved benefits.

In one example, the backsheet can be composed of a necked fiber, acreped fiber, a micro-pleated fiber, polymer films or the like, as wellas combinations thereof. The fabrics may be woven or nonwoven materials,such as spunbond fabrics.

In various constructions, the top sheet 64 can include various woven ornonwoven materials and laminates, which can be stretchable orextensible. In one embodiment, the top sheet 64, shown in FIGS. 1-4, isan extensible material, such as a necked spunbond material. For example,the topsheet can be composed of a meltblown or spunbonded web of desiredfibers, and may also be a bonded-carded web. For example, the topsheetand liner can be made of a substantially hydrophobic material, and thehydrophobic material may optionally be treated with a surfactant orotherwise processed to import a desired level of wettability andhydrophilicity. In one particular embodiment of the invention, thetopsheet is a nonwoven, spunbond polypropylene fabric composed of about2.8-3.2 denier fibers formed into a web having a basis weight of about22 gsm and density of about 0.06 gm/cc. The fabric can be surfacetreated with an operative amount of surfactant, such as about 0.28%Triton X-102 surfactant. The surfactant can be applied by anyconventional means, such as spraying, printing, brush coating or thelike. In another embodiment, the top sheet can also include an elasticmaterial, such that it is stretchable.

The retention portion 70 is made of an absorbent material, which can beany material that tends to swell or expand as it absorbs exudates,including various liquids and/or fluids excreted or exuded by the user.For example, the absorbent material can be made of airformed, airlaidand/or wetlaid composites of fibers and high absorbency materials,referred to as superabsorbents. Superabsorbents typically are made ofpolyacrylic acids, such as FAVOR 880 available from Stockhausen, Inc. ofGreensboro, N.C. The fibers can be fluff pulp materials, such asAlliance CR-1654, or any combination of crosslinked pulps, hardwood,softwood, and synthetic fibers. Airlaid and wetlaid structures typicallyinclude binding agents, which are used to stabilize the structure. Inaddition, various foams, absorbent films, and superabsorbent fabrics canbe used as an absorbent material. Various acceptable absorbent materialsare disclosed in U.S. Pat. No. 5,147,343 for Absorbent ProductsContaining Hydrogels With Ability To Swell Against Pressure, U.S. Pat.No. 5,601,542 for Absorbent Composite, and U.S. Pat. No. 5,651,862 forWet Formed Absorbent Composite, all of which are hereby incorporatedherein by reference. Furthermore, the proportion of high-absorbencyparticles can range from about 0 to about 100%, and the proportion offibrous material from about 0 to about 100%. Additionally, highabsorbency fibers can be used such as Oasis type 121 and type 122superabsorbent fibers available from Technical Absorbent Ltd., Grimsby,Lincolnshire, United Kingdom.

In one embodiment, the retention portion suitably comprise a matrix ofhydrophilic fibers, such as a web of cellulosic fluff, mixed withparticles of superabsorbent material. In a particular embodiment, theretention portion 70 comprises a matrix of cellulosic fluff, such aswood pulp fluff, and super-absorbent hydrogel-forming particles. Thewood pulp fluff may be exchanged with synthetic, polymeric, melt-blownfibers or with a combination of meltblown fibers and natural fibers. Thesuperabsorbent particles may be substantially homogeneously mixed withthe hydrophilic fibers or may be nonuniformly mixed. The fluff andsuperabsorbent particles may also be selectively placed into desiredzones of the retention portion 70 to better contain and absorb bodyexudates. The concentration of the superabsorbent particles may alsovary through the thickness of the retention portion. Alternatively, theretention portion 70 may comprise a laminate of fibrous webs andsuperabsorbent material or other suitable means of maintaining asuperabsorbent material in a localized area.

As explained above, the retention portion may have any of a number ofshapes, including for example and without limitation a rectangularshape, an I-shape (with enlarged end portions (see FIG. 1)), or aT-shape. It is generally preferred that the retention portion benarrower in the crotch area than in the front or rear portions of thegarment. The size and the absorbent capacity of the retention portion 70should be compatible with the size of the intended wearer and the liquidloading imparted by the intended use of the absorbent article. Forexample, the retention portion may have an enlarged end portion at thefront body panel, for example T-shaped, when being used in garmentsdesigned for men. For example, in one embodiment, the enlarged endportion is at least 10% wider than a stem portion, and in anotherembodiment, at least 20% wider. In one embodiment, the retention portionis rectangular and has a width of from about 2 inches to about 8 inches.

The high-absorbency material can be selected from natural, synthetic,and modified natural polymers and materials. The high-absorbencymaterials can be inorganic materials, such as silica gels, or organiccompounds, such as crosslinked polymers. The term “crosslinked” refersto any means for effectively rendering normally water-soluble materialssubstantially water insoluble but swellable. Such means can include, forexample, physical entanglement, crystalline domains, covalent bonds,ionic complexes and associations, hydrophilic associations such ashydrogen bonding, and hydrophobic associations or Van der Waals forces.Examples of synthetic, polymeric, high-absorbency materials include thealkali metal and ammonium salts of poly(acrylic acid) andpoly(methacrylic acid), poly(acryla-mides), poly(vinyl ethers), maleicanhydride copolymers with vinyl ethers and alpha-olefins, poly(vinylpyroli-done), poly(vinyl morpholinone), poly(vinyl alcohol), andmixtures and copolymers thereof. Further polymers suit-able for use inthe absorbent core include natural and modified natural polymers, suchas hydrolyzed acrylonitrile-grafted starch, acrylic acid grafted starch,methylcellulose, carboxymethyl cellulose, hydroxypropyl cellulose, andthe natural gums, such as alginates, xanthumgum, locust bean gum, andthe like. Mixtures of natural and wholly or partially syntheticabsorbent polymers can also be useful in the present invention. Suchhigh-absorbency materials are well known to those skilled in the art andare widely commercially available. Other examples of superabsorbentpolymers suitable for use in the present invention are Hysorb 8800 andSP-9394 polymers available from BASF Corp. located in Mount Olive, N.J.The high absorbency material may be in any of a wide variety ofgeometric forms. As a general rule, it is preferred that the highabsorbency material be in the form of discrete particles. However, thehigh absorbency material may also be in the form of fibers, flakes,rods, spheres, needles, or the like. As a general rule, the highabsorbency material is present in the absorbent body in an amount offrom about 5 to about 90 weight percent based on total weight of theretention portion 70. In one suitable embodiment, the retention portioncontains at least 20% super absorbent material based on the total weightof the absorbent body, more suitably between about 20% and about 90%super absorbent material, even more suitably between about 30% and about80% super absorbent material, and most suitable between about 40% andabout 70% super absorbent material.

Optionally, a substantially hydrophilic tissue wrap-sheet (notillustrated) may be employed to help maintain the integrity of theairlaid fibrous structure of the retention portion. The tissue wrapsheetis typically placed about the retention portion over at least the twomajor facing surfaces thereof and composed of an absorbent cellulosicmaterial, such as creped wadding or a high wet-strength tissue. In oneaspect, the tissue wrapsheet can be configured to provide a wickinglayer which helps to rapidly distribute liquid over the mass ofabsorbent fibers comprising the absorbent body. In another aspect, thewrapsheet material on one side of the absorbent fibrous mass may bebonded to the wrapsheet located on the opposite side of the fibrousmass.

The retention portion preferably can be made of a single or dual layerof absorbent material. The retention portion can include a folded ormulti-layered configuration. Likewise, the entire absorbent insert canhave a folded configuration, with various folds formed from one or moreof the backsheet, top sheet, retention portion or other components. Theretention portion can have a length substantially equal to, or slightlyshorter than, the length of the absorbent insert. The retention portioncan include one or more barrier layers attached to the absorbentmaterial. In one embodiment, an upper tissue wrapsheet or substrate 74is disposed adjacent the retention portion, with a lower tissuesubstrate 75 disposed adjacent an opposite side of the retentionportion. Of course, as explained above, the tissue can completelyenvelope the retention position.

In one desired embodiment, the retention portion has a density in therange of 0.10 gm/cc to 0.50 gm/cc as measured using a circular 3-inchdiameter platen applying 0.2 psi pressure.

In addition, in one desired embodiment, the superabsorbent material hasa centrifuge retention capacity (CRC) in the range of at least about 20grams liquid per gram weight of superabsorbent material, more suitablyat least about 23 grams liquid per gram weight of superabsorbentmaterial, still more suitably about 25 grams liquid per gram weight ofsuperabsorbent material and even more suitably at least about 28 gramsliquid per gram weight of superabsorbent material.

The Centrifuge Retention Capacity is defined by a Test that measures theability of the gel particles (e.g., such as the surface treatedabsorbent material or the superabsorbent material prior to being surfacetreated) to retain liquid therein after being saturated and subjected tocentrifugation under controlled conditions. The resultant retentioncapacity is stated as grams of liquid retained per gram weight of thesample (g/g). The sample to be tested is prepared from particles whichare prescreened through a U.S. standard 30 mesh screen and retained on aU.S. standard 50 mesh screen. As a result, the sample comprisesparticles sized in the range of about 300 to about 600 microns. Theparticles can be prescreened by hand or automatically and are stored ina sealed airtight container until testing.

The retention capacity is measured by placing 0.2±0.005 grams of theprescreened sample into a water-permeable bag which will contain thesample while allowing a test solution (0.9 weight percent sodiumchloride in distilled water) to be freely absorbed by the sample. Aheat-sealable tea bag material, such as that available from DexterCorporation of Windsor Locks, Conn., U.S.A., as model designation 1234Theat sealable filter paper works well for most applications. The bag isformed by folding a 5-inch by 3-inch sample of the bag material in halfand heat-sealing two of the open edges to form a 2.5-inch by 3-inchrectangular pouch. The heat seals should be about 0.25 inches inside theedge of the material. After the sample is placed in the pouch, theremaining open edge of the pouch is also heat-sealed. Empty bags arealso made to serve as controls. Three samples (e.g., filled and sealedbags) are prepared for the test. The filled bags must be tested withinthree minutes of preparation unless immediately placed in a sealedcontainer, in which case the filled bags must be tested within thirtyminutes of preparation.

The bags are placed between two Teflon® coated fiberglass screens having3 inch openings (Taconic Plastics, Inc., Petersburg, N.Y.) and submergedin a pan of the test solution at 23 degrees Celsius, making sure thatthe screens are held down until the bags are completely wetted. Afterwetting, the samples remain in the solution for about 30±1 minutes, atwhich time they are removed from the solution and temporarily laid on anon-absorbent flat surface. For multiple tests, the pan should beemptied and refilled with fresh test solution after 24 bags have beensaturated in the pan.

The wet bags are then placed into the basket of a suitable centrifugecapable of subjecting the samples to a g-force of about 350. Onesuitable centrifuge is a Heraeus LaboFuge 400 having a water collectionbasket, a digital rpm gauge, and a machined drainage basket adapted tohold and drain the bag samples. Where multiple samples are centrifuged,the samples must be placed in opposing positions within the centrifugeto balance the basket when spinning. The bags (including the wet, emptybags) are centrifuged at about 1,600 rpm (e.g., to achieve a targetg-force of about 350), for 3 minutes. The bags are removed and weighed,with the empty bags (controls) being weighed first, followed by the bagscontaining the samples. The amount of solution retained by the sample,taking into account the solution retained by the bag itself, is thecentrifuge retention capacity (CRC) of the sample, expressed as grams offluid per gram of sample. More particularly, the retention capacity isdetermined as: ${CRC} = \frac{\begin{matrix}{{{sample}\text{/}{bag}\quad{weight}\quad{after}\quad{centrifuge}} -} \\{{{empty}\quad{bag}\quad{weight}\quad{after}\quad{centrifuge}} -} \\{{dry}\quad{sample}\quad{weight}}\end{matrix}}{{dry}\quad{sample}\quad{weight}}$

The three samples are tested and the results are averaged to determinethe centrifuge retention capacity (CRC). The samples are tested at 23±1degrees Celsius at 50±2 percent relative humidity.

Referring to FIGS. 1, 5 and 6, the body chassis has a terminal frontwaist edge 20, a terminal back waist edge 28 longitudinally spaced fromthe terminal front waist edge and a first length L1 defined between theterminal front waist edge 20 and the terminal back waist edge 28. Thebody chassis further includes a laterally extending centerline 113defined halfway between the terminal front and back waist edges 20, 28.The retention portion 70, which is formed from the absorbent material,defines a retention region 119. The retention region has first andsecond longitudinally spaced boundaries, defined by the first and secondends 115, 117 of the retention portion in one embodiment, and a secondlength L2 defined between the first and second boundaries. The secondlength L2 is less than or equal to 50% of the first length L1, and atleast 70% of the second length L2 is positioned between the centerline113 and the terminal front waist edge 20.

Moreover, in a desired configuration, there is no absorbent materialdisposed longitudinally outside of the retention region defined betweenthe first and second boundaries 115, 117, meaning there is no absorbentmaterial disposed between the first boundary 115 and the front waistedge 20, or between the second boundary 117 and the rear waist edge 28.Of course, it should be understood that the retention portion 70 canextend all of the way to the front waist edge 20, such that the frontwaist edge and the first boundary 115 are coextensive.

The combination of the size of the retention portion (less than or equalto 50% of the overall length of the garment) and the positioning thereof(at least 70% being positioned forward of the centerline 113) providesfor a garment that is particularly well suited for male users. In thisway, the retention portion can be made smaller and at less cost, yetstill provide maximum protection for the male user. This is particularlytrue when the retention portion is made at least in part fromsuperabsorbent materials, which have increased capacity over other typesof absorbent materials.

In another aspect, the manufacturer or retailer of the afore-describedabsorbent garments provides instructional information to the user, forexample by way of textual or pictorial indicia on the packagingmaterials, about how the garment works. For example, the manufacturer orretailer can explain to the end user the advantages of the variableadhesive regions, and the resultant advantages associated therewith.

Although the present invention has been described with reference tovarious embodiments, those skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention. As such, it is intended that the foregoingdetailed description be regarded as illustrative rather than limitingand that it is the appended claims, including all equivalents thereof,which are intended to define the scope of the invention.

1. A disposable absorbent garment comprising: a body chassis having aterminal front waist edge, a terminal back waist edge longitudinallyspaced from said terminal front waist edge, a first length definedbetween said terminal front waist edge and said terminal back waistedge, and a laterally extending centerline defined half way between saidterminal front and back waist edges; and an absorbent insert fixedlysecured to said body chassis, said absorbent insert comprising aretention region comprising an absorbent material, said retention regionhaving first and second longitudinally spaced boundaries and a secondlength defined between said first and second boundaries, wherein saidsecond length is less than or equal to 50% of said first length, whereinat least 70% of said second length is positioned between said centerlineand said terminal front waist edge, and wherein there is no absorbentmaterial disposed longitudinally outside of said retention regiondefined between said first and second boundaries.
 2. The disposableabsorbent garment of claim 1 wherein said absorbent insert comprises asingle retention member defining said retention region, said retentionmember having first and second ends corresponding to said first andsecond boundaries.
 3. The disposable absorbent garment of claim 1wherein said absorbent material comprises a superabsorbent material. 4.The disposable absorbent garment of claim 3 wherein said superabsorbentmaterial forms at least 20% of the absorbent material by weight.
 5. Thedisposable absorbent garment of claim 3 wherein said superabsorbentmaterial centrifuge retention capacity of at least 20 grams liquid pergram weight of superabsorbent material.
 6. The disposable absorbentgarment of claim 3 wherein said retention portion has a density betweenabout 0.10 gm/cc and about 0.50 gm/cc.
 7. The disposable absorbentgarment of claim 1 wherein said body chassis comprises a front bodypanel comprising said terminal front waist edge and a terminal crotchedge longitudinally spaced from said terminal front waist edge, and arear body panel comprising said terminal back waist edge and a terminalcrotch edge longitudinally spaced from said terminal back waist edge,said terminal crotch edges of said front and rear body panels beinglongitudinally spaced to form a gap therebetween, and wherein saidabsorbent insert comprises first and second longitudinally spaced endportions and opposite laterally spaced side edges, wherein saidabsorbent insert bridges said gap between said front and rear bodypanels with said first and second end portions overlying and connectedto said front and rear body panels respectively.
 8. The disposableabsorbent garment of claim 1 wherein said body chassis comprises anon-woven material.
 9. The disposable absorbent garment of claim 8wherein said body chassis further comprises an elastic material, whereinsaid body chassis is stretchable in at least a lateral direction. 10.The disposable absorbent garment of claim 1 further comprising at leasta pair of fasteners positioned at one end of said body chassis onopposite sides thereof, wherein said at least said pair of fastenersreleasably engages an opposite end of said body chassis on said oppositesides thereof with a pair of leg openings being defined at least in partby said body chassis.
 11. A disposable absorbent garment comprising: afront body panel comprising a terminal waist edge and a terminal crotchedge; a rear body panel comprising a terminal waist edge and a terminalcrotch edge, wherein said terminal crotch edge of said rear body panelis longitudinally spaced from and forms a gap with said terminal crotchedge of said front body panel, and wherein a first length is definedbetween said terminal waist edge of said front body panel and saidterminal waist edge of said rear body panel, and wherein a laterallyextending centerline is defined half way between said terminal waistedges of said front and rear body panels; and an absorbent insertcomprising first and second longitudinally spaced end portions andopposite laterally spaced side edges, wherein said absorbent insertbridges said gap between said front and rear body panels with said firstand second end portions overlying and connected to said front and rearbody panels respectively, said absorbent insert comprising a retentionmember formed from an absorbent material, said retention member havingfirst and second longitudinally spaced ends and a second length definedbetween said first and second ends, wherein at least 70% of said secondlength is positioned between said centerline and said terminal waistedge of said front body panel.
 12. The disposable absorbent garment ofclaim 11 wherein said second length is less than or equal to 50% of saidfirst length.
 13. The disposable absorbent garment of claim 11 whereinsaid absorbent material comprises at least 20% superabsorbent materialby weight.
 14. The disposable absorbent garment of claim 11 wherein eachof said front and rear body panels comprises a non-woven material. 15.The disposable absorbent garment of claim 14 wherein each of said frontand rear body panels further comprises an elastic material, wherein eachof said front and rear body panels are stretchable in at least a lateraldirection.
 16. The disposable absorbent garment of claim 11 furthercomprising at least a pair of fasteners connected to one of said frontand rear body panels, wherein said at least said pair of fastenersreleasably engages the other of said front and rear body panels.
 17. Amethod of assembling a disposable absorbent garment comprising:providing a body chassis having a terminal front waist edge, a terminalback waist edge longitudinally spaced from said terminal front waistedge, a first length defined between said terminal front waist edge andsaid terminal back waist edge, and a laterally extending centerlinedefined half way between said terminal front and back waist edge; andfixedly securing an absorbent insert to said body chassis, wherein saidabsorbent insert comprising a retention region comprising an absorbentmaterial, said retention region having first and second longitudinallyspaced boundaries and a second length defined between said first andsecond boundaries, wherein said second length is less than or equal to50% of said first length, wherein at least 70% of said second length ispositioned between said centerline and said terminal front waist edge,and wherein there is no absorbent material disposed outside of saidretention region defined between said first and second boundaries. 18.The method of claim 17 wherein said absorbent insert comprises a singleretention member defining said retention region, said retention memberhaving first and second ends corresponding to said first and secondboundaries.
 19. The method of claim 17 wherein said absorbent materialhas at least 20% superabsorbent material by weight.
 20. The method ofclaim 17 wherein said body chassis comprises a front body panelcomprising said terminal front waist edge and a terminal crotch edgelongitudinally spaced from said terminal front waist edge, and a rearbody panel comprising said terminal back waist edge and a terminalcrotch edge longitudinally spaced from said terminal back waist edge,said terminal crotch edges of said front and rear body panels beinglongitudinally spaced to form a gap therebetween, and wherein saidabsorbent insert comprises first and second longitudinally spaced endportions and opposite laterally spaced side edges, and wherein saidfixedly securing said absorbent insert to said body chassis comprisesbridging said gap between said front and rear body panels with absorbentinsert wherein said first and second end portions overlie said front andrear body panels respectively, and fixedly securing said first andsecond end portions to said front and rear body panels respectively. 21.The method of claim 17 wherein said body chassis comprises a non-wovenmaterial.
 22. The method of claim 21 wherein said body chassis furthercomprises an elastic material, wherein said body chassis is stretchablein at least a lateral direction.
 23. The method of claim 17 furthercomprising providing at least a pair of fasteners positioned at one endof said body chassis on opposite sides thereof, wherein said at leastsaid pair of fasteners are releasably engageable with an opposite end ofsaid body chassis on said opposite sides thereof.